Equipment list had in metrology lab 1.

Vernier Caliper

a. Fixed measuring jaw b. Measuring surfaces c. Movable measuring jaw d. Metric vernier scale e. Main graduation scale f. Depth measuring rod g. Blade measuring surfaces h. Graduated beam MEASURING ACCURACY Basically, there are three types of the standard vernier scale available. They are 1/10mm, 1/20mm, and 1/50mm. a. Measuring accuracy of the Tenth Value Vernier On the main scale, a distance of 10mm is divided into 10 equal parts, thus the distance between markings = 1 mm. On the vernier scale, 9mm is divided into 10 parts, thus the distance between markings = 0.9mm. Therefore, measuring accuracy (graduation difference) = 1mm - 0.9mm = 0.1mm

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b. Measuring accuracy of the Twentieth Value Vernier

On the main scale, a distance of 20mm is divided into 20 equal parts, thus the distance between marking = 1mm. On the vernier scale, 19mm is divided into 20 parts, thus the distance between marking = 0.95. Therefore, measuring accuracy = 1mm - 0.95mm = 0.05mm READING THE SCALE Example of read-off ; 1. Tenth value vernier, One division is represented as 1mm on the main scale and for the vernier scale, one division is represented as 0.1mm. The mark 0 on the vernier scale shows that the distance measured is more than 21 mm. Reading the graduation on the vernier scale which coincides exactly with the main scale is 0.6mm. Measurement result: 21mm + 0.6mm = 21.6mm

2. Twentieth value vernier Measurement result: 73mm + 0.6mm + 0.05mm = 73.65mm

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2. Micrometer i. External micrometer It is used to check external dimensions such as the diameter of a shaft and thickness of a work piece. It consists of a fixed anvil and a movable spindle. The anvil can be made of carbide which has a very flat surface. The object to be measured is positioned between the fixed anvil and the measuring surfaces. Both measuring surfaces are very accurately ground. Parts of an external micrometer

A. Anvil B. Measuring Surfaces C. Movable spindle D. Ratchet E. Thimble F. Sleeve G. U-shaped frame with insulator plate (to prevent heat transfer from hands) Measuring range The length of the threads on the measuring spindle is usually 25mm. This means that the measuring ranges of the external micrometer are stepped at every 25mm. The measuring ranges of the micrometer are divided into: Measuring accuracy There are 50 graduations on the thimble for the micrometer with 0.5mm pitch on the spindle. If the thimble is rotated one complete revolution, the spindle will move 0.5mm. Thus, one graduation on the thimble scale represents 0.01 mm. Measuring accuracy = 0.5 spindle pitch 50 graduations = 0.01 mm

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Sources of errors a. Misreading - most common misreading is by 0.5mm, incorrectly counting sleeve graduations. b. Dirt, nicks, durrs, oil, etc., on the anvil and spindle will prevent proper contact and cause inaccurate reading. c. Wear and damage on the anvil and spindle. d. Pitch errors - the screw of the spindle is worn out. e. Miscalibrate - the zero setting is set wrongly. f. Applied too much force when measuring. ii. Internal Micrometer It is used to check internal dimensions such as diameter of a hole and width of a slot. It comes with different designs, ranges, and shapes depending on its applications. Internal Micrometer with central locking device

It consists of a single micrometer head and series of extension measuring rods to provide a large measurement range (35 - 1 25mm). It has round measuring surfaces to provide better contact point on the round wall. Generally it has a measuring accuracy of 0.01mm. To read off the measured value is the same as the external micrometer. Guidelines when using Internal Micrometer Calibrate the instrument by means of a ring gauge. Hold the instrument against the hole wall and move the measuring surfaces about while locking the instrument to locate the center of the hole. Ensure the instrument is located perpendicular to the hole center line. Apply only light pressure to ensure good contact.

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Sources of errors

Bend and worn out measuring rod. Improperly assembled extension measuring rod. Instrument is not located perpendicular to the hole center line (common error).

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3. Dial Indicator PRINCIPLE OF A DIAL INDICATOR (PLUNGER TYPE) The principle of the dial indicator is to amplify the movement of the plunger with a small displacement to give a large deflection of the pointer by means of toothed rack and gears. The transmission ratio is usually 100 : 1. Thus,a small value of displacement by the plunger can be read directly or detected very accurately as it is amplified on the measuring scale. Amplification = movement of the pointer on scale movement of plunger = 80mm/0.8mm = 100 : 1

PARTS OF A DIAL INDICATOR A. Measuring insert B. Plunger C. Clamping shank D. Small dial face (1 div = 1mm) E. Rotating scale (1 div = 0.01mm) F. Setting ring

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HOW DOES A DIAL INDICATOR WORK. It operates based on gears and the rack principle. A rack with a pitch of 0.625mm is cut on the plunger which is than meshed with a pinion (small gear) with 16 teeth. On a pinion, a small pointer and a large gear with 100 teeth is connected to it in which they share a common shaft. Another small gear with 10 teeth - which carries a long pointer - is meshed with a large gear which has 100 teeth at the center of the dial indicator. Thus, any movement of the plunger is amplified to the pointer in which it will show the measurement value on a graduated scale. MEASURING ACCURACY

One completed turn on pinion = One completed turn on large gear Thus, one completed turn on pinion , the plunger will move = 16 teeth x 0.625= 10mm One completed turn on large gear = 10 turns on the small gear (10 teeth) 10 turns on the small gear = 10mm.Thus, one complete turn on the small gear = 10mm divided by 10 teeth= 1mm.However, there are 100 divisions on the rotating scale; Therefore, 1 division on rotating scale = 1mm divided by 100 divisions = 0.01mm

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READING THE SCALE On a small dial face, 1 division represents 1mm On a rotating scale, 1 division represents 0.01mm Refer to the diagram: Small pointer is just before 2; Reading = 1mm Large pointer is at 0.89mm Thus, measurement result = 1.89mm

GUIDELINES WHEN USING DIAL INDICATOR a. Calibrate it at frequent intervals for accuracy by using gauge blocks. b. Clamp the dial indicator securely on holder of measuring stand. c. Keep the measuring insert clean and free from dirt. d. Ensure that it stands vertically to surface of workpiece. e. Avoid excessive pressure when applying the measuring insert to the surface of workpiece. f. Avoid dropping it and store it at a proper place when it is not used.

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SOURCES OF ERRORS

a. Damage on the measuring insert and worn out of the gear teeth. b. Dial indicator is not positioned perpendicular to the surface of the workpiece - cosine error. c. Misreading - a person using a dial gauge that makes more than one revolution must be aware of how many revolutions the pointer has made when taking the measurement. d. The dial indicator is not clamped and secured properly. This will cause vibrations.

APPLICATIONS OF DIAL INDICATOR a. To measure the thickness of a work piece by using comparative method.

b. To measure flatness of workpiece surface.

c. To measure roundness of a shaft.

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d. To measure straightness of a shaft.

e. To measure parallelism of a work piece.

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4.

High Gauge A Surface Plate must always be used in conjunction with numerous measuring instruments, accessories and holding devices. The commonly and widely used accessories or holding devices to the surface plate are vernier height gauge, dial gauge, gauge blocks, parallel bars, V-block, angle plate, sine-bar, precision vice, precision try-square, cylindrical pin, and etc. These holding devices come in many shapes or designs to enable holding parts in horizontal, vertical, and angular planes. They must be kept clean and free from burrs and nicks. When necessary a fine stone can be used to clean and remove burrs. The prime concern is their flatness, squareness and parallelism. Types of Height Gauges Generally, height gauges may be classified into three types: a. vernier height gauge b. dial height gauge c. digital height gauge a) Vernier Height Gauge

The vernier height gauge is a self-supporting measuring instrument which consists of a heavy base with a vertical vernier scale similar to that on a vernier caliper. It is easily adjustable over a large range. To read-off the measured value is the same as a vernier caliper. It is mainly used in conjunction with a surface plate for marking or lay-out the workpiece when the scriber is attached. It can also be used to measure the height of the workpiece. A dial gauge may be attached to the height gauge to provide greater accuracy in measurement by means of comparative method with the help of a Master Height Gauge.

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Sources of errors a. The slide arm is not parallel with the base. b. An unclean and damaged base causes inaccuracy. c. The scriber is worn-out. d. The height gauge is not calibrated properly. When you check for accuracy always ensure that the zero mark of the vernier and main scale coincide when the base of the scriber makes contact flat with the surface plate. Alternatively we can use a gauge block and compare it with the scale of the height gauge. e. Avoid parallax errors. When you read the measured value, always look vertical to the scale. Guidelines for using a Vernier Height Gauge a. Always ensure that the height gauge had been calibrated. b. Clean the height gauge and surface plate entirely before use. c. Hold the base firmly to the surface plate to avoid tipping. Always lock the main scale when in use. d. Move the height gauge slowly and gently. Do not slam it around. e. Clamp the scriber as near as possible to the column. This will increase accuracy and less vibration. f. A dial gauge may be attached to provide greater accuracy. Application of the Vernier Height Gauge It is always used in conjunction with a surface plate and it can be used for marking the workpiece with a scriber attached to it.

Normally, a dial gauge is attached to it to provide better accuracy.

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5. Profile projector Introduction Profile projector is a large optical instrument which projects a workpiece surface or contour on a screen for dimensional measurements (linear and angular measurements) and observation. The part to be measured is mounted on a table that can be moves in X and Y directions by accurate micrometer screws. The profile projector projects the image of the part on a screen, magnifying it from 5 to more than 100 times. Measurements can be made directly, either by means of the micrometer dials, digital readouts or on the magnified image on the screen by means of a n accurate scale or template (chart)

1. Control panel 2. Focusing knob 3. Table fine feed knob 4. Table core feed knob 5. Projection lens 6. Screen rotation knob 7. Projection screen 8. Table elevation wheel 9. Contour illuminator 10. Table 11. Surface illuminator 12. Angle counter

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APPLICATION Profile projector is a multi-purpose measuring instrument used for checking length, angle, radius, diameter, thread pitch and gear profiles. TEST PROCEDURES There are three methods of testing : a. Projection by contour illumination b. Projection by surface illumination c. Projection by both the contour and surface illumination

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